Engineering Standard

SAES-Q-012 Criteria for Design and Construction of Precast and Prestressed Concrete Structures Civil Standards Committee Members
Mehthel, Mohammed Heshan, Chairman Idi, Saleh Hamad, Vice Chairman Abu-Adas, Hisham A.W. Moumen, Abdulmajeed Abdullah Abulhamayel, Ismat Abdulkader Darwish, Ali Hassan Saffar, Saeed Abdullah Grosch, Jonathan Joseph Kassam, Eqbal M.

11 July 2006

Saudi Aramco DeskTop Standards

Table of Contents

1 2 3 4 5 6 7 8 9 10

Scope............................................................. 2 Conflicts and Deviations................................ 2 References..................................................... 2 Design............................................................ 5 Materials........................................................ 8 Fabrication.................................................... 11 Delivery, Storage and Handling of Material.. 13 Erection........................................................ 13 Inspection and Testing................................. 14 Offshore Concrete Structures....................... 15

Previous Issue: 1 December 1996 Next Planned Update: 11 July 2011 Revised paragraphs are indicated in the right margin Primary contact: Abu-Adas Hisham A.W. on 966-3-874-6908 CopyrightSaudi Aramco 2005. All rights reserved.

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Document Responsibility: Civil Issue Date: 11 July, 2006 Next Planned Update: 11 July 2011

SAES-Q-012 Criteria for Design and Construction of Precast and Prestressed Concrete Structures

Scope 1.1 This standard covers the design, material specifications, manufacturing and erection of precast and prestressed concrete products including building components such as columns, beams, hollow core slabs, single and double tees, wall panels, decorative fences and marine trestles, etc.

Conflicts and Deviations 2.1 Any conflicts between this standard and other applicable Saudi Aramco Engineering Standards (SAESs), Saudi Aramco Materials System Specifications (SAMSSs), Standard Drawings (SASDs), or industry standards, Codes, and Forms shall be resolved in writing by the Company or Buyer Representative through the Manager, Consulting Services Department of Saudi Aramco, Dhahran. Direct all requests to deviate from this standard in writing to the Company or Buyer Representative, who shall follow internal company procedure SAEP-302 and forward such requests to the Manager, Consulting Services Department of Saudi Aramco, Dhahran.

2.2

References The selection of material and equipment, and the design, construction, maintenance, and repair of equipment and facilities covered by this standard shall comply with the latest edition of the references listed below, unless otherwise noted. 3.1 Saudi Aramco References Saudi Aramco Engineering Procedure (SAEP) SAEP-302 Instructions for Obtaining a Waiver of a Mandatory Saudi Aramco Engineering Requirements

Saudi Aramco Engineering Standards (SAES) SAES-H-101 SAES-M-100 SAES-Q-001 SAES-Q-005 SAES-Q-010 Approved Protective Coating Systems Saudi Aramco Building Code Criteria for Design and Construction of Concrete Structures Concrete Foundations Cement Based, Non-Shrink Grout for Structural and Equipment Grouting
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SAES-Q-012 Criteria for Design and Construction of Precast and Prestressed Concrete Structures

SAES-Q-011

Epoxy Grout for Machinery Support

Saudi Aramco Materials System Specifications (SAMSS) 09-SAMSS-088 09-SAMSS-097 09-SAMSS-106 3.2 Industry Codes and Standards Prestressed Concrete Institute (PCI) PCI MNL-116 Manual for Quality Control for Plants and Production of Precast and Prestressed Concrete Products, Fourth Edition Manual for Quality Control for Plants and Production of Architectural Precast Concrete Products, Third Edition PCI Design Handbook - Precast and Prestressed Concrete, Sixth Edition, 2004 Manual for Structural Design of Architectural Precast Concrete, Second Edition Tolerance Manual for Precast and Prestressed Concrete Construction Aggregates for Concrete Ready-Mixed Portland Cement Concrete Epoxy Coating of Steel Reinforcing Bars

PCI MNL-117

PCI MNL-120 PCI MNL-122 PCI MNL-135

American Concrete Institute (ACI) ACI 201.2R ACI 211.1 ACI 211.2 ACI 305R ACI 318M ACI 347R ACI 515.1R Guide to Durable Concrete Standard Practice for Selecting Proportions for Normal, Heavyweight, and Mass Concrete Standard Practice for Selecting Proportions for Structural lightweight concrete Hot Weather Concreting Building Code Requirements for Reinforced Concrete Guide to Formwork for Concrete Guide to the use of Waterproofing, Dampproofing, Protective and Decorative Barrier Systems for Concrete

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ACI 517.2R ACI SP-66

Accelerated Curing of Concrete at Atmospheric Pressure-State of the Art Detailing Manual Details and Detailing of Concrete Reinforcement

American Society for Testing and Materials (ASTM) ASTM A36 ASTM A53 Standard Specification for Carbon Structural Steel Standard Specification for Pipe, Steel, Black and Hot-Dipped, Zinc-Coated, Zinc Coated, Welded and Seamless Standard Specification for Structural Bolts, Steel, Heat Treated, 120/105 ksi Minimum Tensile Strength Standard Specification for Steel Strand, Uncoated Seven-Wire for Prestressed Concrete Standard Specification for Zinc-Coated (Galvanized) Steel Bars for concrete Reinforcement Standard Specification for Epoxy-Coated Reinforcing Bars Standard Specification for Epoxy-Coated Steel Wire and Welded Wire Fabric for Reinforcement Standard Specification for Structural Steel Shapes Standard Test Method for Compressive Strength of Cylindrical Concrete Specimens Standard Specification for Lightweight Aggregates for Structural Concrete Test for Acid-Soluble Chloride in Mortar and Concrete

ASTM A325

ASTM A416 ASTM A767

ASTM A775 ASTM A884

ASTM A992/A992M ASTM C39 ASTM C330 ASTM C1152

American Welding Society (AWS) AWS D1.1 AWS D1.4 Structural Welding Code - Steel Structural Welding Code - Reinforcing Steel

British Standards Institution (BS) BS 1881 Part 124 Methods for Analysis of Hardened Concrete

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SAES-Q-012 Criteria for Design and Construction of Precast and Prestressed Concrete Structures

Saudi Arabian Standards Organization (SASO) SSA-2/1992 SSA-224/1981 4 Design 4.1 Structural design of all members and their connections shall be the responsibility of the Contractor. The design shall be performed by qualified and competent structural engineer. The design shall be in accordance with ACI 318/318M, PCI Design Handbook (MNL-120) and PCI Manual (MNL-122). Prior to precast concrete fabrication, structural design calculations, design drawings and shop drawings including lifting details and capacities (Safe Working Load SWL) shall be submitted to Saudi Aramco for review and approval. Such review shall not relieve the precast concrete Manufacturer of any design responsibility. The Prestressed Concrete Institute (PCI) Design Handbook shall be the basis for analysis and design of precast and prestressed concrete structures. Compressive Strength For standard weight concrete, the minimum 28 day design compressive strength shall be 34.5 MPa (5000 psi). The minimum cement content for precast concrete shall be per Section 5.1 below. Release strength for prestressed unit shall be 24.1 MPa (3500 psi) minimum. For lightweight concrete, the minimum 28 day design compressive strength shall be 34.5 MPa (5000 psi) and air-dry density of not less than 14.14 Kn/m (90 lbs/ft) nor more than 18.07 Kn/m (115 lbs/ft). 4.5 Minimum Floor & Roof Live Loads Floor and roof live loads shall be per SAES-M-100 "Saudi Aramco Building Code". 4.6 Precast concrete work shall be designed to carry all dead and superimpose loads indicated, including hanging loads and lateral loads, including loads arising from storage, handling and transportation. Camber and Deflection Design flexural members with sufficient camber to properly offset deflection under superimposed dead loads, which should be shown on design drawings. Steel Bars for the Reinforcement of Concrete Steel Fabric for Reinforcement of Concrete

4.2

4.3 4.4

4.7

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4.8

The proportions of ingredients in the concrete mix shall be selected in accordance with provisions of ACI 211.1 for normal weight concrete and ACI 211.2 for lightweight concrete. The water cement ratio (w/c) shall not exceed 0.40. ACI 201.2R "Guide to Durable Concrete" shall be used to specify special concreting and concrete protection requirements. Concrete exposure to corrosive materials, stray electrical current and abrasion shall be determined, and special protection for the concrete and reinforcement shall be provided. The Contractor shall submit design drawings and structural design calculations to Saudi Aramco representative for review and approval. The design calculations shall include the following: 4.10.1 4.10.2 4.10.3 4.10.4 4.10.5 4.10.6 Stresses in members due to bending, shear, compression, tension, and torsion caused by vertical loads, prestressing forces and handling. Stresses at release of prestressing force. Camber and deflection. Ultimate capacity of the members. Stresses in members due to shrinkage, creep, and thermal expansion. Secondary stresses due to prestressing force.

4.9

4.10

4.11

The design of the bearings and connections shall take into account tolerances allowed in the construction and erection of members as per PCI/ACI specifications and the stresses due to shrinkage, creep, thermal expansion and contraction, and deflection of members being connected. Concrete Cover The minimum concrete cover for Prestressed Concrete is listed in ACI 318-02 Sections 7.7.2 as listed in Table 1.3.6 of PCI Design Handbook. For Precast Concrete manufactured under plant control conditions, the minimum concrete cover shall be as listed below:

4.12

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Concrete Cover For Precast Concrete Condition Exposed to earth or weather Wall Panels 25 mm 40 mm 50 mm Minimum Cover

Slabs and Joists

Beams and columns

Not Exposed to earth or weather Wall panels, slabs and joists Beams and columns 25 mm 50 mm 75 mm

Concrete exposed to sea water, raw water or sewage 4.13

Galvanized welded wire fabric is not recommended for members subject to chlorides. When galvanized reinforcement is used in concrete, it should not be coupled directly to un-galvanized steel reinforcement, copper, or other dissimilar materials. Galvanized reinforcement should be fastened with ties of soft stainless steel, or zinc coated or nonmetallic coated tie wire. The maximum acid soluble chloride ions and sulfates as SO3 in concrete shall not exceed 0.25% and 4% (by weight of cement) respectively, when tested in accordance with ASTM C1152 or BS 1881 Part 124 or equivalent. Welding The details of welded joints for embedded plates shall conform to the requirements of the latest edition of AWS D1.1, "Structural Welding Code". Welding shall be in accordance with AWS D1.4 for reinforcing steel.

4.14

4.15

4.16

Anchor Bolts and Embedded Items 4.16.1 4.16.2 The design of anchor bolts shall be in accordance with paragraph 4.8 of SAES-Q-005. Metallic sleeves are not allowed and anchor bolts shall not be in contact with reinforcing steel.
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4.16.3

All sleeves, inserts, anchor bolts, waterstops and other embedded items shall be installed in accordance with the design/fabrication drawings and supported against displacement. Plate inserts shall be placed with 6.0 mm (1/4 in) horizontal tolerances (same plane as finished surface) and 1.0 mm (1/32 in) vertical tolerance (in plane from finished face). Projecting steel items (such as grating angles, slide plates, unistrut, steel plates, etc.) which are attached to the formwork and cast at the concrete surface shall be hot dip galvanized. Additionally, the steel bar which anchors these items to the concrete shall be similarly galvanized. Reinforcing steel bars, anchor bolts or other steel embedment shall not be used as the means for grounding electrical equipment and shall not be tied to grounding neutral conductors, or any part of the lightning protection system. Conduits, pipes and other items made from aluminum shall not be embedded in structural concrete unless effectively coated to prevent aluminum-concrete reaction.

4.16.4

4.16.5

4.16.6

4.16.7

Materials The concrete materials shall be in accordance with 09-SAMSS-097 "Ready-Mixed Portland Cement Concrete" and as follows: 5.1 Cement Portland cement type shall be per Section 5.1 - Table 1 of SAES-Q-001 "Criteria for Design and Construction of Concrete Structures". The minimum cement content for precast concrete shall be 370 Kg/M of concrete.
Commentary Note: No maximum cement content is specified for precast concrete. It is usually common practice to specify cement content of more than 370 Kg/M of concrete in the precast concrete industry.

5.2

Aggregates Aggregates used in concrete shall be per 09-SAMSS-088 "Aggregate for Concrete". For lightweight concrete, aggregates shall be in accordance with ASTM C330.

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5.3

Water Quality of water in concrete shall be per Section 5.1.3.1 and Table A of 09-SAMSS-097 "Ready-Mixed Portland Cement Concrete".

5.4

Admixtures Admixtures used in concrete shall be per Section 5.1.7 of 09-SAMSS-097 "Ready-Mixed Portland Cement Concrete". Calcium chloride as an admixture shall not be used in precast and prestressed concrete.

5.5

Epoxy Grout Epoxy grout shall be per SAES-Q-011 "Epoxy Grout for Machinery Support".

5.6

Non-Shrink Grout Cement-based non-shrink grout shall be per SAES-Q-010 "Cement Based, NonShrink Grout for Structural and Equipment Grouting".

5.7

Pigments Pigments or other coloring agents, when required, shall be resistant to lime and other alkalis.

5.8

Reinforcing Bars Reinforcing steel bars shall conform to SASO SSA-2, hot-rolled, high tensile, deformed steel. These bars shall be acceptable under the ACI 318M specified limitation of 422 MPa (60 ksi). ACI 318M reinforcing specifications are based on ASTM metric standards. Bar supports shall be solid plastic and bar ties shall be nylon wire. Reinforcing steel type shall be per Table 1 of SAES-Q-001.

5.9

Galvanized welded wire fabric shall conform to ASTM A767 and shall be acceptable reinforcement in lieu of epoxy coated welded wire fabric coated in accordance with ASTM A884. Coated reinforcement shall be Fusion bonded Epoxy in accordance with 09-SAMSS-106. Manufacture, fabrication, handling, placement and storage of reinforcement shall be in accordance with chapter 7 of ACI 318. Handling and fabrication of the Epoxy coated reinforcement shall be in accordance with ASTM A775 Appendix, and Concrete Reinforcing Steel Institute (CRSI).

5.10 5.11

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Document Responsibility: Civil Issue Date: 11 July, 2006 Next Planned Update: 11 July 2011 Commentary Note:

SAES-Q-012 Criteria for Design and Construction of Precast and Prestressed Concrete Structures

Care should be taken to avoid any damage to the coated rebars during shipment, handling, fabrication and placement of the coated rebars. The extent of the damage and repair of the coating shall be in accordance with 09-SAMSS-106.

5.11

Welded Wire Fabric Welded wire fabric shall conform to SASO SSA-224, (cold drawn) wire with a minimum yield strength of 240 MPa (34.8 ksi).

5.12

Prestressing Tendons Strands shall be uncoated, 7-wire "low relaxation" strand conforming to ASTM A416 with a minimum strength of 250,000 psi (Grade 250) unless grade 270 is indicated. Epoxy coated strands shall not be used for prestressed concrete.

5.13

Formwork Provide forms necessary to produce the required finish surfaces and precast units of the shapes, lines and dimensions indicated, within the required fabrication tolerances. Forms shall be of sufficient strength to withstand pressures due to fabrication operations. Forms shall be free of noticeable wrinkles, dents, patches, and other such defects. Contact surface of forms shall be clean, free of ruts and other roughness. Form joints shall be tight and free of defects. Provisions shall be made that all temporary handling items be invisible in the finished product work and protected against deterioration due to the elements. The design and construction of the formwork shall be in accordance with ACI 347R and Saudi Aramco Construction Safety Manual. For forms removal for precast members, refer to paragraph 7.6.5 of ACI 347R-03.

5.14

Connection Material Provide plates and shapes required for the support of precast units, either embedded in the shop or shipped loose, as shown on the drawings or as required. Provide steel plates or shapes galvanized after assembly. Structural steel material shall be as follows:

Steel plates: Structural quality, hot-rolled carbon steel, ASTM A36 Steel shapes (W and WT): ASTM A992/A992M Steel pipe: ASTM A53, Type E or S, Grade B, galvanized. Provide high strength, ASTM A325, galvanized steel bolts, nuts, and washers for connections.

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Provide standard stainless steel threaded inserts in terms of all single and double tee roof members complete with removable plastic caps, spacing to be 1220 mm (4'-0") on center (o.c.) throughout capable of carrying 4.45 Kn (1,000 pound) per insert. Additional inserts to be provided as shown on drawings.

Fabrication 6.1 All precast prestressed concrete members shall be fabricated in accordance with Prestressed Concrete Institute, Manual for Quality Control for Plants and Production of Precast Prestressed Concrete Products MNL-116. Before shipment, all concrete members shall be inspected and approved by the Manufacturer's Quality Control Department to make certain that the materials and workmanship conform to the requirements of these specifications. All architectural precast concrete members shall be fabricated in accordance with Prestressed Concrete Institute, Manual for Quality Control for Plants and Production of Architectural Precast Concrete Products MNL-117. Before shipment, all concrete members shall be inspected and approved by the Manufacturer's Quality Control Department to make certain that the materials and workmanship conform to the requirements of these specifications. All precast concrete shall be cast in watertight forms of metal, wood, concrete or other suitable materials to provide a standard finish with a dense texture, free of honeycombing and excess air holes. Surface texture shall be uniform and shall be standard finish of concrete placed against steel or other dense surface. All concrete surfaces in direct contact with earth shall be coated with two coats of coal tar or bitumen coating that conforms to APCS-3 or APCS-10 of SAESH-101. Where concrete surface protection is required it shall be in accordance with ACI 515.1R.
Commentary Note: APCS-10 shall not be used where soil is contaminated with hydrocarbons.

6.2

6.3

6.4

6.5

All precast members where the reinforcement protrudes through the surface or where shadow lines caused by reinforcement too near the surface shall be rejected. Dimensional tolerances shall not exceed those recommended in the PCI Manual of Quality Control (MNL-116, MNL-117 and MNL-135) with the following exceptions:

6.6

Wall panels shall have no camber and differential bowing between adjacent panels shall not exceed 3 mm ( of an inch). Total maximum bowing due to
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thermal stresses, etc., shall not exceed 1/360 of panel length.

Differential camber between adjacent members other than wall panels shall not exceed 10 mm ( of an inch). Where the differential camber exceeds this value, a fill shall be installed and feathered out on a 1-in-12 slope. Differential camber between adjacent members for Prestressed Concrete Double Tees shall not exceed 6 mm ( of an inch).

6.7 6.8

Chamfer shall be provided at exposed edges of columns and beams unless shown otherwise. Reinforcing steel, where required, shall be supported with plastic or galvanized chairs. However, the use of PVC Schedule 80 pipe as spacer is allowed. The PVC pipe shall be notched at the bottom to allow the ingress of concrete. Typical samples shall be submitted for supervisor of Civil Engineering Unit/CSD for approval. Reinforcement detailing shall be in accordance with ACI SP-66. Finishing 6.9.1 6.9.2 Finish of exterior surfaces shall be in accordance with the Project Specifications and as shown on contract drawings. All lifting devices shall be recessed. Lifting devices shall be removed and patched to match interior surface of panel after installation is complete, and to the acceptance of Saudi Aramco Representative.

6.9

6.10

Curing 6.10.1 Steam curing can be used for precast concrete. It shall be in accordance with ACI 517.2R "Accelerated Curing of Concrete at Atmospheric Pressure State of the Art". When water curing is used, it shall be in accordance with Section 10 of SAES-Q-001. Curing compound shall not be used for curing of precast and prestressed concrete elements.

6.10.2 6.10.3 6.11 Samples

Samples showing various finishes as required and specified for the project shall be submitted in sufficient number until a control sample for each finish is approved by Saudi Aramco Representative. Submit for approval 400 mm by 400 mm by 40 mm (16 inch by 16 inch by 1- inch) samples of precast concrete
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units. A full size panel or member shall be prepared at the plant to be reviewed and approved by Saudi Aramco Representative. This approval sample shall be retained and used for reference as the standard for quality, color and texture for the Project. 6.12 Openings in Precast and Prestressed Units Location of openings for ducts, exhaust fans, cable trays, piping, etc. shall be inspected, checked and verified against design drawings during fabrication of all precast and prestressed concrete members. 7 Delivery, Storage and Handling of Material 7.1 Prestressed concrete members shall be lifted and supported only at the lifting and support points shown on the shop drawings during handling, storing, and transporting. Proper equipment and methods of bracing shall be used during transporting to ensure the members shall arrive at the jobsite undamaged. Members damaged by handling, transporting, or storing shall be rejected and replaced with undamaged members without any expense to Saudi Aramco. Members shall be kept free of mud and other damaging materials at all times, and shall be stored at the jobsite on non-staining wooden pallets or platforms in such a manner to ensure drainage and drying when exposed to the elements. Store and transport members in a manner to prevent the occurrence of excessive stresses or cracking. Lift and support units at the designate lift points only. Store molds in such a manner to protect them from damage that could result in dimensional change or general surface or structural degradation.

7.2

7.3 7.4

Erection 8.1 Prior to the erection of any precast member, the structural component to which the member is to be attached shall be checked for elevation and alignment. Acceptable deviations in these structural components shall be dimensionally compensated for when erecting the precast members. All precast members shall be installed in proper sequence and adequate temporary supports shall be provided to control alignment, deflection, and stress levels. Precast units shall be lifted during erection only at the lifting points shown on the shop drawings. All lifting devices shall be removed from erected precast units. Precast members shall be grouted where called for on the drawings. The space to be occupied by the grout shall be thoroughly cleaned, removing all dirt, oil,
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8.2

8.3

Document Responsibility: Civil Issue Date: 11 July, 2006 Next Planned Update: 11 July 2011

SAES-Q-012 Criteria for Design and Construction of Precast and Prestressed Concrete Structures

grease and loose material. The grout shall be mixed in accordance with the manufacturer's specifications. 8.4 Anchor members to supporting bearing surfaces as shown on the design Drawings. Members shall be anchored together at intervals along their length as recommended by manufacturer. Welding of members shall be at places shown on the drawings or where required and by approved welders. Precast units shall be lifted during erection only at the lifting points shown on the shop drawings. All lifting devices shall be removed from erected precast units. Field-Placed Inserts 8.6.1 Field-placed inserts, such as hand-drilled or power driven inserts and studs, may not be placed in members unless approved by Saudi Aramco Representative. The installation of field-placed inserts shall not interfere with prestressing steel. Power driven inserts and studs shall be located an adequate distance from concrete edges and corners to prevent spalling. Field cutting or drilling holes in the stems of double tees is not allowed. Field cutting openings in the flanges of double tees to be limited to one 600 mm by 600 mm (2'-0" by 2'-0") opening per panel unless approved by Saudi Aramco Representative. Field cutting in solid wall panels shall be limited to 250 mm (10-inch) round opening unless approved by Saudi Aramco Representative.

8.5

8.6

8.6.2 8.6.3

8.6.4 8.7

All precautions shall be taken to avoid damage to other work. Any work or materials damaged to such extent that they cannot be restored to their original condition shall be replaced. All prestressed concrete members shall be erected into final position by competent erection personnel, erection equipment and methods acceptable to the Fabricator and under the direct on-site Technical Guidance of the Fabricator. When hot weather condition exists, concrete shall be placed in compliance with ACI 305R.

8.8

8.9

Inspection and Testing Inspection and testing shall be in accordance with Section 16 of SAES-Q-001. Supplier shall institute Quality Control procedures for the manufacture, inspection and testing of
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precast units in compliance with PCI-MNL-116 and PCI-MNL-117. Furnish certification of Quality Control test results. 9.1 Quality control for the production of precast prestressed concrete shall be per the "Manual for Quality Control for Plants and Production of Precast and Prestressed Concrete Products" PCI-MNL-116. Quality control for the production of architectural precast concrete shall be per the "Manual for Quality Control for Plants and Production of Architectural Precast Concrete Products" PCI-MNL-117. Performance Evaluation Precast units may be rejected for any of the following:

9.2

9.3

Defects as listed in PCI MNL-116, as applicable Surfaces with finish deficiencies Damage during lifting, transporting and construction operations Excessive dimensional variations

9.4

Defective Work Repair as per approved repair procedure submitted by manufacturer or replace precast units which do not conform to the specified requirements. The Supplier shall be responsible for the cost of correcting other work affected by or resulting from corrections to the precast concrete work.

10

Offshore Concrete Structures A full environmental evaluation for concrete marine structures shall be performed per Section 17 of SAES-Q-001. The evaluation shall include identification of marine organisms including rock boring mollusks and sponges that would pose a threat to the precast and prestressed concrete structure and its integrity.

11 July 2006

Revision Summary Reissue as major revision.

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